Classifications

• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C17/00—Preparation of halogenated hydrocarbons
  • C07C17/25—Preparation of halogenated hydrocarbons by splitting-off hydrogen halides from halogenated hydrocarbons
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
  • B01J27/06—Halogens; Compounds thereof
  • B01J27/08—Halides
  • B01J27/10—Chlorides
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C17/00—Preparation of halogenated hydrocarbons
  • C07C17/013—Preparation of halogenated hydrocarbons by addition of halogens
  • C07C17/04—Preparation of halogenated hydrocarbons by addition of halogens to unsaturated halogenated hydrocarbons
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P20/00—Technologies relating to chemical industry
  • Y02P20/10—Process efficiency

Definitions

• the present disclosure relates to processes for the production of chloroalkenes.
• the present disclosure relates to catalytic dehydrochlorination of chloroalkanes using a solid catalyst, a catalyst deposited on a solid substrate, or combinations thereof.
• Chlorocarbons in particular, chlorinated propenes are used as feedstocks for the manufacture of hydrofluoroolefin (HFO) products, polyurethane blowing agents, biocides, and polymers, among other chemical products.
• HFO hydrofluoroolefin
• many chlorinated propenes have limited commercial availability or are available only at a prohibitively high cost due in part to the multi-step processes typically utilized in their manufacture.
• conventional processes may involve multiple chlorination and dehydrochlorination steps to arrive at a desired level of chlorination in the final product.
• the dehydrochlorination of chlorocarbons may be carried out using dissolved metal chloride catalysts, requiring subsequent distillation or separation of the chemical product from the catalyst. The presence of such dissolved catalytic components can produce further undesired reactions prior to and during the distillation process. It would thus be desirable to provide improved processes for the production of chlorocarbons useful as feedstocks in the synthesis of commercial chemical products.
• the present disclosure provides a process for the production of a chloroalkene.
• the process includes contacting a liquid phase first chloroalkane with a solid catalyst, a catalyst deposited on a solid substrate, or combinations thereof, thereby causing dehydrochlorination of the first chloroalkane to produce a first chloroalkene product and HCI.
• FIG. 1 shows the percentage conversion of 1 , 1 , 1 ,3-tetrachloropropane versus temperature after being contacted with 5.6g of 30 weight percent ZnC catalyst on a carbon substrate, at a flow rate of 0.33 cc/min and at a pressure of 170 psig;
• FIG. 2 shows the percentage trichloropropene selectivity versus temperature after 1 , 1 , 1 ,3-tetrachloropropane was contacted with 5.6g 30 weight percent ZnC catalyst on a carbon substrate, at a flow rate of 0.33 cc/min and at a pressure of 170 psig;
• FIG. 3 shows the percentage conversion of 1 , 1 , 1 ,3-tetrachloropropane versus temperature after being contacted with a 5g y-type molecular sieve as catalyst, at a flow rate of 0.33 cc/min and at a pressure of 170 psig, with and without simultaneous chlorination of the trichloropropene product by sulfuryl chloride;
• FIG. 4 shows the percentage trichloropropene selectivity versus temperature after 1 , 1 , 1 ,3-tetrachloropropane was contacted with a 5g y-type molecular sieve as catalyst, at a flow rate of 0.33 cc/min and at a pressure of 170 psig, with and without simultaneous chlorination of the trichloropropene product by sulfuryl chloride;
• FIG. 5 shows the percent conversion of 1 , 1 , 1 ,3-tetrachloropropane, percent trichloropropene selectivity, and production rate in g/H versus time in the presence of 5g y-type molecular sieve as catalyst, at a flow rate of 0.33 cc/min and at a pressure of 170 psig, with and without simultaneous chlorination of the trichloropropene product by sulfuryl chloride;
• FIG. 6 shows the percentage conversion of 1 , 1 , 1 ,3-tetrachloropropane, percentage trichloropropene selectivity, feed rate in g/H, and temperature versus time in the presence of 4.9g 13X molecular sieve in the form of 16X40 mesh beads, at a flow rate of 0.33 cc/min and at a pressure of 170 psig; and
• FIG. 7 shows the percentage conversion of 1 , 1 , 1 ,3-tetrachloropropane, percentage trichloropropene selectivity, feed rate in g/H, and temperature versus time in the presence of 4.2g 22.9 percent by weight FeC catalyst on activated carbon, at a flow rate of 0.33 cc/min and at a pressure of 100 psig.
• percent (%) conversion is meant to indicate change in molar or mass flow of reactant in a reactor in ratio to the incoming flow
• percent (%) selectivity means the change in molar flow rate of product in a reactor in ratio to the change of molar flow rate of a reactant.
• the present disclosure generally relates to a process for the production of a chloroalkene by catalytic dehydrochlorination of a chloroalkane using a solid catalyst or a catalyst deposited on a solid support.
• the process may include contacting a liquid phase first chloroalkane with a solid catalyst, a catalyst deposited on a solid substrate, or combinations thereof, thereby causing dehydrochlorination of the first chloroalkane to produce a first chloroalkene product and HCI.
• the catalyst may include a metal chloride deposited on a solid substrate. Suitable metal chlorides may include, but are not limited to, ZnC FeC , AICI3, CuC and combinations thereof.
• the catalyst may include more than one metal chloride, including, but not limited to, metal chlorides having different metal oxidation states.
• the catalyst may include a mixture of ZnC and FeC or a mixture of FeC and FeC .
• the catalyst may include a reduced (zero- valence) metal, such as Cu or Fe.
• Suitable solid substrates may include, but are not limited to, substrates comprising carbon, alumina, silica, titania, an aluminosilicate, a zeolite, and combinations thereof.
• the solid substrate may include a molecular sieve, including, but not limited to, an aluminosilicate molecular sieve, a zeolite molecular sieve, a Y-type molecular sieve, a 13X molecular sieve, and combinations thereof.
• the metal chloride or reduced metal catalysts may be used in any combination with any suitable solid substrate without departing from the spirit and scope of the present disclosure.
• ZnC FeC , CuC or any combination thereof may be deposited on a carbon substrate or may be deposited on a different solid substrate, such as alumina, silica, titania, an aluminosilicate, a zeolite, or combinations thereof.
• the presently disclosed process may further include reacting at least a portion of the first chloroalkene product with a chlorinating agent to form at least some of a second chloroalkane product.
• a chlorinating agent may include, but are not limited to, chlorine gas, liquid chlorine, sulfuryl chloride, and combinations thereof.
• the chlorinating agent is essentially dry, i.e., it has a water content of the below 1000 ppm. Lower water concentrations are preferred, but not required.
• the dehydrochlonnation of the first chloroalkane and the chlorination of the first chloroalkene product may occur contemporaneously, or nearly contemporaneously.
• the first chloroalkene product may be chlorinated as soon as the first chloroalkene product is produced by the dehydrochlonnation of the first chloroalkane.
• the dehydrochlonnation of the first chloroalkane and the chlorination of the first chloroalkene product occurs contemporaneously in the same vessel, in different sections of the same vessel, or in separate vessels.
• the dehydrochlonnation of the first chloroalkane may be conducted at a temperature of from about 0°C to about 200°C. In at least some instances, the dehydrochlonnation of the first chloroalkane may be conducted at a temperature of from about 25°C to about 170°C. In other cases, a suitable temperature for the dehydrochlonnation of the first chloroalkane may be from about 80°C to about 150°C.
• the dehydrochlonnation of the first chloroalkane may desirably occur at temperatures between 25°C and 170°C, or between 50°C and 170°C, or between 75°C and 170°C, or between 100°C and 170°C, or between 125°C and 170°C, or between 150°C and 170°C.
• the dehydrochlorination of the first chloroalkane may desirably occur at temperatures between 80°C and 150°C, or between 90°C and 150°C, or between 100°C and 150°C, or between 1 10°C and 150°C, or between 120°C and 150°C, or between 130°C and 150°C, or between 140°C and 150°C.
• the dehydrochlorination of the first chloroalkane may be further conducted at a pressure of from about 0 psig to about 200 psig.
• the pressure must be high enough to ensure that at least some of the first chloroalkane is in liquid phase during the dehydrochlorination reaction.
• the dehydrochlorination of 1 , 1 ,1 ,3- tetrachloropropane may be conducted at the minimum pressure required to ensure that most of the 1 , 1 , 1 ,3-tetrachloropropane is in liquid phase at the selected temperature of reaction.
• the dehydrochlorination of the first chloroalkane may be conducted at a pressure and temperature in which the first or second chloroalkane is in liquid phase.
• Liquid feed rates during the dehydrochlorination of the first or second chloroalkane may be from about 0.001 to about 1 cc/min/g catalyst.
• the presently disclosed process may further include additional dehydrochlorination reactions conducted under the same conditions described above with respect to the dehydrochlorination of the first chloroalkane.
• the process may further include dehydrochlorinating the second chloroalkane to produce at least some second chloroalkene.
• the dehydrochlorination of the second chloroalkane may include contacting the second chloroalkane, in liquid phase, with a solid catalyst, a catalyst deposited on a solid substrate, or combinations thereof, thereby causing dehydrochlorination of the second chloroalkane to produce at least some second chloroalkene and HCI.
• the dehydrochlorination of the second chloroalkane may include contacting the second chloroalkane with a homogeneous catalyst or a combination of a homogeneous catalyst and a solid catalyst or a catalyst supported on a solid substrate.
• the chloroalkene product of the second dehydrochlonnation reaction, or any other additional dehydrochlonnation reaction may be chlorinated by one or more additional chlorination reactions to form an additional chlorinated alkane product.
• the second chloroalkene may be chlorinated in the same manner described with reference to the chlorination of the first chloroalkene product to produce a third chloroalkane product or one or more additional chloroalkane products.
• the first and second dehydrochlorinations may occur under different reaction conditions. In other cases, the first and second dehydrochlorinations may occur under the same or substantially the same reactions conditions.
• the first chloroalkane may be a dichloropropane, trichloropropane, a tetrachloropropane, a pentachloropropane, a hexachloropropane, or combinations thereof.
• trichloropropanes, tetrachloropropanes, pentachloropropanes, and hexachloropropanes include, but are not limited to 1 , 1 - dichloropropane; 1 ,2-dichloropropane; 1 ,3-dichloropropane; 1 ,1 , 1 -trichloropropane;
• the process may include 1 , 1 , 1 ,3-tetrachloropropane and mixtures of 1 , 1 , 1 ,3-tetrachloropropane as the liquid phase first chloroalkane.
• the first chloroalkene product may include
• the second chloroalkane may be a pentachloropropane, such as 1 ,1 , 1 ,2,3- pentachloropropane.
• the second chloroalkene may be a tetrachloropropene, such as 1 , 1 ,2,3-tetrachloropropene (1230xa).
• Suitable reaction conditions for the presently disclosed process, or portions thereof, include temperatures from about 0°C to about 200°C.
• suitable temperatures may be from about 25°C to about 170°C or from about 80°C to about 150°C.
• Suitable pressures for the presently disclosed process, or portions thereof, include pressures from about 0 psig to about 200 psig.
• the solid catalyst, catalyst deposited on a solid substrate, or combinations thereof may be contained in a reactor.
• the presently disclosed process, or any portion of the presently disclosed process may occur in a reactor.
• different portions of the presently disclosed process may occur in different reactors.
• the reactor may be any suitable liquid phase reactor, such as a batch, semi-batch, or continuous stirred tank reactor. Suitable reactors may include a packed bed reactor, a packed bed column reactor, a continuous stirred tank reactor, a reactive distillation system, a shell and multitube reactor, and combinations thereof.
• the solid catalyst, catalyst deposited on a solid substrate, or combinations thereof may be contained in a packed bed reactor.
• the presently disclosed process may include feeding the liquid phase first chloroalkane into a packed bed reactor having a first end and a second end.
• the chloroalkane feed may be fed from either the first end or the second end of the bed of the packed bed reactor.
• the process may include a chloroalkane feed into a packed bed column reactor from either the top of the column or the bottom of the column.
• the solid catalyst, catalyst deposited on a solid substrate, or combinations thereof may be contained in a stirred tank reactor.
• the process may further include removing at least a portion of the first chloroalkene product as a gas or vapor.
• the pressure of the reactor may be controlled such that at least some of the first chloroalkene product is caused to flash from the liquid phase to a vapor and exit the reactor as a vapor.
• the dehydrochlorination reaction may occur in a reactive distillation system such that at least some of the first chloroalkene product is removed as a vapor and at least some of the reaction liquid comprising the first chloroalkane and heavy by-products is removed as a liquid.
• the process may include removing chloroalkene products as they are formed, using a reactive distillation system, thereby reducing catalyst fouling and deactivation.
• the presently disclosed process may be carried out in a shell and multitube reactor capable of near-isothermal operation.
• the shell and multi-tube reactor may include a shell having a diameter of several meters that contains from as few as about 5000 tubes up to as many as about 50,000 reaction tubes. Each reaction tube may be as long as 5, 10, or even 15 meters.
• desired reactant gases or liquids are supplied to the inlet chamber at the upper ends of the reactor tubes and passed therethrough. Effluents leaving the lower ends of the reactor tubes are collected in the effluent collecting head. The heat of reaction is removed by a heat transfer fluid which is passed across the outer surfaces of the reactor tubes.
• the presently disclosed process may occur in a shell and multitube reactor configured to maintain the temperature during the dehydrochlorination reaction.
• the solid catalyst, catalyst deposited on a solid substrate, or combinations thereof may be contained in one or more of the tubes in the reactor.
• Near isothermal conditions may be maintained during the dehydrochlorination reaction using a heat transfer fluid that may include, but is not limited to, heated oil or steam.
• a process for the production of 1 , 1 ,1 ,2,3-pentachloropropane includes contacting 1 , 1 , 1 ,3-tetrachloropropane in liquid phase with a solid catalyst, a catalyst deposited on a solid substrate, or combinations thereof, thereby causing dehydrochlorination of the 1 , 1 , 1 ,3-tetrachloropropane to produce at least one trichloropropene product and HCI.
• the process further includes reacting at least a portion of the trichloropropene product with a chlorinating agent to form at least some 1 , 1 , 1 ,2,3-pentachloropropane.
• the trichloropropene product may include 1 , 1 ,3-trichloropropene, 3,3,3-trichloropropene, 1 ,2,3-trichloropropene, and mixtures thereof.
• Suitable solid catalysts or catalysts deposited on a solid substrate are the same as those previously described with respect to the dehydrochlonnation of the first chloroalkane.
• a process for the production of 1 ,1 ,2,3-tetrachloropropene (1230xa) includes contacting 1 , 1 , 1 ,3-tetrachloropropane in liquid phase with a solid catalyst, a catalyst deposited on a solid substrate, or combinations thereof, thereby causing dehydrochlonnation of the 1 , 1 , 1 ,3-tetrachloropropane to produce at least one trichloropropene product and HCI.
• the process further includes reacting at least a portion of the trichloropropene product with a chlorinating agent to form at least some 1 , 1 , 1 ,2,3-pentachloropropane.
• the process further includes contacting the 1 , 1 , 1 ,2,3-pentachloropropane in liquid phase with a homogeneous catalyst (e.g., metal chlorides of iron, aluminum, tin and/or antimony), a solid catalyst, a catalyst deposited on a solid substrate, or combinations thereof, thereby causing dehydrochlonnation of the 1 , 1 , 1 ,2,3-pentachloropropane to produce at least some 1 , 1 ,2,3-tetrachloropropene.
• a homogeneous catalyst e.g., metal chlorides of iron, aluminum, tin and/or antimony
• the trichloropropene product may include 1 , 1 ,3-trichloropropene, 3,3,3-trichloropropene, 1 ,2,3-trichloropropene, and mixtures thereof.
• Suitable solid catalysts or catalysts deposited on a solid substrate are the same as those previously described with respect to the dehydrochlonnation of the first chloroalkane.
• the process may further include distilling or otherwise purifying one or more of the chloroalkene products or chloroalkane products after such products are removed from the reactor.
• one or more of the chloroalkene or chloroalkane products may be purified by stripping.
• a stripping gas or vapor may be used to strip the chloropropene products from the higher-boiling chloropropane starting material.
• a stripping gas or vapor may be introduced to the reactor or reactive distillation system.
• the stripping gas may be HCI gas that is produced as a byproduct of the reaction.
• the process may further include recycling one or more of the chloroalkane products or chloroalkene products after distilling or purifying back into the process.
• recycling one or more chloroalkane products and/or chloroalkene products increased efficiency, increased through-put, and a lower unit manufacturing cost can be attained.
• the presently disclosed process may cause the conversion of between about 10% and about 100% of the first or second chloroalkane to chloroalkene product.
• the percent (%) conversion of first or second chloroalkane to chloroalkene product achieved according to the presently disclosed process may be in the range of a lower limit of about 10%, 15%, 20%, 25%, 30%, 35%, 40%, and 50%, to an upper limit of about 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95% and 100%, encompassing any value and subset therebetween.
• the percent (%) conversion of first or second chloroalkane to chloroalkene product achieved according to the presently disclosed process may be in the range of a lower limit of about 10%, 15%, and 20%, to an upper limit of about 25%, 30%, and 35%, encompassing any value and subset therebetween.
• the presently disclosed process is conducted under reaction conditions sufficient to achieve at least 90% conversion of the first or second chloroalkane to chloroalkene product. In other cases, the presently disclosed process may be conducted under reaction conditions sufficient to achieve at least 85% conversion of the first or second chloroalkane to chloroalkene product. In yet other instances, the process may be conducted under reaction conditions sufficient to achieve at least 75% conversion of the first or second chloroalkane to chloroalkene product.
• the presently disclosed process including dehydrochlorination of a chloroalkane to produce a chloroalkene by contacting a liquid phase chloroalkane with a solid catalyst, a catalyst deposited on a solid substrate, or combinations thereof, provides advantages over conventional dehydrochlorination processes that use dissolved catalysts, such as dissolved metal chlorides.
• a solid catalyst or a catalyst deposited on a solid substrate obviates the need to distill or otherwise separate the chloroalkene products from the dissolved catalyst.
• the elimination of the need for dissolved catalytic components has the additional advantage of preventing further undesired catalytic reactions that may occur prior to or during the distillation or separation process.
• processes for the conversion of the chloroalkenes such as 1 , 1 ,2,3-tetrachloropropane, and/or the chloroalkanes, such as 1 , 1 , 1 ,2,3-pentachloropropane, to one or more hydrofluoroolefins.
• These processes comprise contacting the chloroalkene and/or chloroalkane with a fluorinating agent in the presence of a fluorination catalyst, in a single reaction or two or more reactions.
• These processes can be conducted in either gas phase or liquid phase with the gas phase being preferred at temperatures ranging from 50°C to 400°C.
• fluorinating agents can be used.
• fluorinating agents include HF, F 2 , CIF, AIF 3 , KF, NaF, SbF 3 , SbF 5 , SF 4 , or combinations thereof.
• the skilled artisan can readily determine the appropriate fluorination agent and catalyst.
• hydrofluoroolefins examples include, but are not limited to 2,3,3,3- tetrafluoroprop-1 -ene (HFO-1234yf), 1 ,3,3,3-tetrafluoroprop-1 -ene (HFO-1234ze), 3,3,3-trifluoroprop-1 -ene (HFO-1243zf), and 1 -chloro-3,3,3-trifluoroprop-1 -ene (HFCO-1233zd).
• a catalyst comprising 5.6g of 30 weight percent ZnC deposited on a carbon solid substrate was charged to a 25.4 cm long Monel tube having a 0.77 cm internal diameter. Both ends of the Monel tube were fitted with screens to hold the catalyst inside the tube. The catalyst was purged with nitrogen for 2 hours at 200°C. The temperature was reduced to 100°C and liquid phase 1 , 1 , 1 ,3-tetrachloropropane was fed to the Monel tube at a flow rate of 0.33 cc/min. Pressure was controlled at 170 psig. Temperature was varied and samples of the liquid exiting the tube were collected at different temperatures and analyzed by gas chromatography. FIG. 1 shows the percentage conversion of 1 , 1 , 1 ,3-tetrachloropropane versus temperature while FIG. 2 shows the percentage trichloropropene selectivity versus temperature.
• a catalyst comprising 5g y-type molecular sieve was charged to a 25.4 cm long Monel tube having a 0.77 cm internal diameter. Both ends of the Monel tube were fitted with screens to hold the catalyst inside the tube. The catalyst was purged with nitrogen for 2 hours at 200°C. The temperature was reduced to 100°C and liquid phase 1 ,1 , 1 ,3-tetrachloropropane was fed to the Monel tube at a flow rate of 0.33 cc/min. Pressure was controlled at 170 psig. Temperature was varied and samples of the liquid exiting the tube were collected at different temperatures and analyzed by gas chromatography.
• FIG. 3 shows the percentage conversion of 1 , 1 , 1 ,3- tetrachloropropane versus temperature while FIG. 4 shows the percentage trichloropropene selectivity versus temperature, with and without simultaneous chlorination of the trichloropropene product by sulfuryl chloride.
• a catalyst comprising 4.9g 13X molecular sieve in the form of 16x40 mesh beads was charged to a 25.4 cm long Monel tube having a 0.77 cm internal diameter. Both ends of the Monel tube were fitted with screens to hold the catalyst inside the tube. The catalyst was purged with nitrogen for 2 hours at 200°C. The temperature was reduced to 100°C and liquid phase 1 , 1 , 1 ,3-tetrachloropropane was fed to the Monel tube at a flow rate of 0.33 cc/min. Pressure was controlled at 170 psig. Temperature was varied and samples of the liquid exiting the tube were collected at different temperatures and analyzed by gas chromatography. FIG.
• a catalyst comprising 4.2g 22.9 weight percent FeC on activated carbon was charged to a 25.4 cm long Monel tube having a 0.77 cm internal diameter. Both ends of the Monel tube were fitted with screens to hold the catalyst inside the tube. The catalyst was purged with nitrogen for 1 hour at 200°C. The temperature was reduced to 100°C and liquid phase 1 , 1 , 1 ,3-tetrachloropropane was fed to the Monel tube at a flow rate of 0.33 cc/min. Pressure was controlled at 100 psig. Temperature was varied and samples of the liquid exiting the tube were collected at different temperatures and analyzed by gas chromatography. FIG.

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• 2017
  • 2017-06-22 US US16/311,761 patent/US20190169100A1/en not_active Abandoned
  • 2017-06-22 CN CN201780037698.6A patent/CN109311785A/zh active Pending
  • 2017-06-22 JP JP2018567573A patent/JP2019522000A/ja active Pending
  • 2017-06-22 CA CA3027504A patent/CA3027504A1/en not_active Abandoned
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